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By NASA
4 Min Read NASA 3D-Printed Antenna Takes Additive Manufacturing to New Heights
The 3D-printed antenna mounted to a ladder prior to testing at NASA's Columbia Scientific Balloon Facility in Palestine, Texas. Credits: NASA/Peter Moschetti In fall 2024, NASA developed and tested a 3D-printed antenna to demonstrate a low-cost capability to communicate science data to Earth. The antenna, tested in flight using an atmospheric weather balloon, could open the door for using 3D printing as a cost-effective development solution for the ever-increasing number of science and exploration missions.
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NASA developed and tested a 3D-printed antenna to demonstrate a low-cost capability to communicate science data to Earth.NASA/Kasey Dillahay Printing
For this technology demonstration, engineers from NASA’s Near Space Network designed and built a 3D-printed antenna, tested it with the network’s relay satellites, and then flew it on a weather balloon.
The 3D printing process, also known as additive manufacturing, creates a physical object from a digital model by adding multiple layers of material on top of each other, usually as a liquid, powder, or filament. The bulk of the 3D-printed antenna uses a low electrical resistance, tunable, ceramic-filled polymer material.
Using a printer supplied by Fortify, the team had full control over several of the electromagnetic and mechanical properties that standard 3D printing processes do not. Once NASA acquired the printer, this technology enabled the team to design and print an antenna for the balloon in a matter of hours. Teams printed the conductive part of the antenna with one of several different conductive ink printers used during the experiment.
For this technology demonstration, the network team designed and built a 3D-printed magneto-electric dipole antenna and flew it on a weather balloon. [JF1] A dipole antenna is commonly used in radio and telecommunications. The antenna has two “poles,” creating a radiation pattern similar to a donut shape.
Testing
The antenna, a collaboration between engineers within NASA’s Scientific Balloon Program and the agency’s Space Communications and Navigation (SCaN) program, was created to showcase the capabilities of low-cost design and manufacturing.
Following manufacturing, the antenna was assembled and tested at NASA’s Goddard Space Flight Center in Greenbelt, Maryland, in the center’s electromagnetic anechoic chamber.
The anechoic chamber is the quietest room at Goddard — a shielded space designed and constructed to both resist intrusive electromagnetic waves and suppress their emission to the outside world. This chamber eliminates echoes and reflections of electromagnetic waves to simulate the relative “quiet” of space.
To prepare for testing, NASA intern Alex Moricette installed the antenna onto the mast of the anechoic chamber. The antenna development team used the chamber to test its performance in a space-like environment and ensure it functioned as intended.
NASA Goddard’s anechoic chamber eliminates echoes and reflections of electromagnetic waves to simulate the relative “quiet” of space. Here, the antenna is installed on the mast of the anechoic chamber.NASA/Peter Moschetti Once completed, NASA antenna engineers conducted final field testing at NASA’s Columbia Scientific Balloon Facility in Palestine, Texas, before liftoff.
The team coordinated links with the Near Space Network’s relay fleet to test the 3D-printed antenna’s ability to send and receive data.
The team monitored performance by sending signals to and from the 3D-printed antenna and the balloon’s planned communications system, a standard satellite antenna. Both antennas were tested at various angles and elevations. By comparing the 3D-printed antenna with the standard antenna, they established a baseline for optimal performance.
Field testing was performed at NASA’s Columbia Scientific Balloon Facility in Palestine, Texas, prior to liftoff. To do this, the 3D-printed antenna was mounted to a ladder.NASA/Peter Moschetti In the Air
During flight, the weather balloon and hosted 3D-printed antenna were tested for environmental survivability at 100,000 feet and were safely recovered.
For decades, NASA’s Scientific Balloon Program, managed by NASA’s Wallops Flight Facility in Virginia, has used balloons to carry science payloads into the atmosphere. Weather balloons carry instruments that measure atmospheric pressure, temperature, humidity, wind speed, and direction. The information gathered is transmitted back to a ground station for mission use.
The demonstration revealed the team’s anticipated results: that with rapid prototyping and production capabilities of 3D printing technology, NASA can create high-performance communication antennas tailored to mission specifications faster than ever before.
Implementing these modern technological advancements is vital for NASA, not only to reduce costs for legacy platforms but also to enable future missions.
The Near Space Network is funded by NASA’s SCaN (Space Communications and Navigation) program office at NASA Headquarters in Washington. The network is operated out of NASA’s Goddard Space Flight Center in Greenbelt, Maryland.
By Kendall Murphy
NASA’s Goddard Space Flight Center, Greenbelt, Md.
About the Author
Kendall Murphy
Technical WriterKendall Murphy is a technical writer for the Space Communications and Navigation program office. She specializes in internal and external engagement, educating readers about space communications and navigation technology.
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Last Updated Jan 22, 2025 EditorGoddard Digital TeamContactKendall Murphykendall.t.murphy@nasa.govLocationGoddard Space Flight Center Related Terms
Manufacturing, Materials, 3-D Printing Goddard Space Flight Center Scientific Balloons Space Communications & Navigation Program Space Communications Technology Technology Explore More
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By NASA
2 Min Read Advanced Modeling Enhances Gateway’s Lunar Dust Defense
A sample holder in a vacuum chamber spins during a lunar dust adhesion test at NASA’s Johnson Space Center. Credits: NASA/Josh Litofsky NASA’s Artemis campaign aims to return humans to the Moon, develop a sustainable presence there, and lay the groundwork for the first crewed missions to Mars. As the agency prepares for longer stays on and around the Moon, engineers are working diligently to understand the complex behavior of lunar dust, the sharp, jagged particles that can cling to spacesuits and jam equipment.
Lunar dust has posed a problem since astronauts first encountered it during the Apollo missions. Ahead of more frequent and intense contact with dust, NASA is developing new strategies to protect equipment as astronauts travel between the Moon and spacecraft like Gateway, humanity’s first lunar space station.
Josh Litofsky, systems engineer at NASA’s Johnson Space Center, scoops material designed to behave like lunar dust to test how it adheres to Gateway materials. NASA/Bill Stafford Unlike Apollo-era spacecraft that faced lunar dust exposure just once, Gateway will encounter it each time a Human Landing System spacecraft returns to the space station from the lunar South Pole region. Dust could enter Gateway’s environment, risking damage to science instruments, solar arrays, robotic systems, and other important hardware.
Josh Litofsky is the principal investigator and project manager leading a Gateway lunar dust adhesion testing campaign at NASA’s Johnson Space Center in Houston. His team tracks how the dust interacts with materials used to build Gateway.
An artist’s rendering of the Gateway lunar space station in polar orbit around the Moon. NASA/Alberto Bertolin “The particles are jagged from millions of years of micrometeoroid impacts, sticky due to chemical and electrical forces, and extremely small,” Litofsky said. “Even small amounts of lunar dust can have a big impact on equipment and systems.”
Litofksy’s work seeks to validate the Gateway On-orbit Lunar Dust Modeling and Analysis Program (GOLDMAP), developed by Ronald Lee, also of Johnson Space Center. By considering factors such as the design and configuration of the space station, the materials used, and the unique conditions in lunar orbit, GOLDMAP helps predict how dust may move and settle on Gateway’s external surfaces.
Josh Litofsky, systems engineer at NASA’s Johnson Space Center, places a sample holder inside a vacuum chamber to test how lunar dust sticks to Gateway materials. NASA/Bill StaffordNASA/Bill Stafford Early GOLDMAP simulations have shown that lunar dust can form clouds around Gateway, with larger particles sticking to surfaces.
The data from these tests and simulations will help NASA safeguard Gateway, to ensure the space station’s longevity during the next era of lunar exploration.
The lessons learned managing lunar dust and other harsh conditions through Gateway and Artemis will prepare NASA and its international partners for missions deeper into the cosmos
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Last Updated Jan 22, 2025 ContactLaura RochonLocationJohnson Space Center Related Terms
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International teams of astronauts will explore the scientific mysteries of deep space with Gateway, humanity’s first space station around the…
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By NASA
With the historic first international space docking mission only six months away, preparations on the ground for the Apollo-Soyuz Test Project (ASTP) intensified. At NASA’s Kennedy Space Center (KSC) in Florida, workers in the Vehicle Assembly Building (VAB) stacked the rocket for the mission, the final Saturn rocket assembled for flight. In the nearby Manned Spacecraft Operations Building (MSOB), the Apollo prime crew of Commander Thomas Stafford, Command Module Pilot Vance Brand, and Docking Module Pilot Donald “Deke” Slayton, and their backups Alan Bean, Ronald Evans, and Jack Lousma conducted vacuum chamber tests of the Command Module (CM), the final Apollo spacecraft prepared for flight.
Inside the Vehicle Assembly Building (VAB) at NASA’s Kennedy Space Center in Florida, workers attach fins to the Saturn IB’s first stage. In the VAB, workers secure the first stage of the Saturn IB rocket onto the milk stool, perched on Mobile Launcher-1. Workers lift the second stage of the Saturn IB rocket prior to mating with the first stage. Workers lower a boilerplate Apollo spacecraft onto the Saturn IB rocket. The Saturn IB rocket, serial number SA-210, used for ASTP had a lengthy history. Contractors originally built its two stages in 1967, at a time when NASA planned many more Saturn IB flights to test Apollo spacecraft components in Earth orbit in preparation for the Moon landing. By 1968, however, after four uncrewed Saturn IB launches, only one launched a crew, Apollo 7. Four more Saturn IBs remained on reserve to launch crews as part of the Apollo Applications Program, renamed Skylab in 1970. Without an immediate mission, the two stages of SA-210 entered long-term storage in 1967. Workers later modified and refurbished the stages for ASTP before shipping them to KSC. The first stage arrived in April 1974 and the second stage in November 1972.
On Jan. 13, 1975, inside the cavernous VAB, workers stacked the Saturn IB rocket’s first stage onto Mobile Launcher-1 (ML-1), modified from its use to launch Saturn V rockets during the Apollo program with the addition of the milk stool pedestal. The milk stool, a 128-foot tall platform, allowed the Saturn IB to use the same Launch Umbilical Tower as the much larger Saturn V rocket at Launch Complex 39. The next day, workers lowered the second stage onto the first, followed by the Instrument Unit two days later. Finally, on Jan. 17 workers topped off the rocket with a boilerplate Apollo spacecraft while engineers continued testing the flight article in the MSOB.
The ASTP Apollo Command and Service Modules arrive at NASA’s Kennedy Space Center (KSC) in Florida. The ASTP Command Module arrives in KSC’s Manned Spacecraft Operations Building. The Command and Service Modules – CSM-111 – arrived at KSC from the Rockwell International plant in Downey, California, on Sept. 8, 1974, by C-5A Galaxy cargo plane. Rockwell had finished building the spacecraft in March 1970 and placed it in storage until July 1972. Modifications for ASTP took place between August 1972 and August 1974, following which Rockwell shipped the spacecraft to KSC. The sign on the shipping container bore the legend “From A to Soyuz – Apollo/Soyuz – Last and the Best.” Workers at KSC towed the modules to the MSOB for inspection and checkout, joined the two modules, and placed the combined spacecraft into a vacuum chamber.
The prime Apollo crew of Thomas Stafford, left, Vance Brand, and Donald “Deke” Slayton suit up in preparation for an altitude chamber test in the Command Module (CM). The astronauts inside the CM in the altitude chamber. In the MSOB, the prime and backup ASTP crews conducted tests of their spacecraft in an altitude chamber. After both crews completed simulated runs in December 1974, the prime crew of Stafford, Brand, and Slayton suited up, entered the CM inside the chamber, closed the hatch, and conducted an actual test on Jan. 14, with the chamber simulating altitudes of up to 220,000 feet. Two days later, the backup crew of Bean, Evans, and Lousma completed a similar test.
he backup Apollo crew of Alan Bean, left, Ronald Evans, and Jack Lousma suit up in preparation for an altitude chamber test in the Command Module (CM). Workers assist backup crewmember Lousma into the CM. To solve the problem of the Apollo and Soyuz spacecraft operating at different atmospheric pressures and compositions and using incompatible docking mechanisms, engineers designed a Docking Module (DM) that acted as both an airlock and a transfer tunnel and a Docking System (DS) that allowed the two nations’ spacecraft to physically join in space. NASA contracted with Rockwell International to build the DM. Engineers equipped one end of the DM with the standard Apollo probe-and-drogue docking mechanism and the other end with the androgynous system that linked up with its opposite half installed on the modified Soyuz spacecraft. During launch, the DM rested inside the Spacecraft Lunar Module (LM) Adaptor (SLA) atop the rocket’s upper stage, much like the LM during Apollo flights. Once in orbit, the astronauts separated the CSM from the upper stage, turned the spacecraft around, docked with the DM and pulled it free.
Workers lower the DM into Chamber B in the Space Environment Simulation Laboratory at NASA’s Johnson Space Center in Houston. Workers lower the DM into Chamber B in the Space Environment Simulation Laboratory at NASA’s Johnson Space Center in Houston. After extensive vacuum testing in Chamber B of the Space Environment Simulation Laboratory at NASA’s Johnson Space Center in Houston, the flight DM arrived at KSC on Oct. 29, 1974, and workers prepared it for more testing in a vacuum chamber in the MSOB. The flight DS arrived at KSC on Jan. 3, 1975, and two weeks later workers installed it on the DM. On Jan. 27, engineers lowered the DM onto the CM in the altitude chamber to conduct a mechanical docking test. Engineers conducted 10 days of joint tests of television and audio equipment to ensure systems compatibility.
Workers conduct a docking test of the Docking Module with the Command Module at NASA’s Kennedy Space Center in Florida. NASA support astronaut Robert Overmyer, right, works with engineers during compatibility testing. To be continued…
Major events around the world in January 1975:
January 5 – Musical The Wiz opens on Broadway, runs for 1,672 performances.
January 6 – The game show Wheel of Fortune debuts on NBC.
January 8 – Ella Grasso of Connecticut becomes the first elected female governor in the U.S.
January 11 – The S-II second stage of the Saturn V rocket that launched Skylab reenters the Earth’s atmosphere over the Indian Ocean.
January 12 – The Pittsburg Steelers beat the Minnesota Vikings in Super Bowl IX, played in Tulane Stadium in New Orleans.
January 15 – Space Mountain opens at Disney World in Orlando.
January 18 – The Jeffersons premieres on CBS.
January 22 – Launch of the Landsat-2 Earth resources monitoring satellite.
January 30 – Ernő Rubik applies for a patent in Hungary for his Magic Cube, later known as Rubik’s Cube.
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By NASA
Creating a golden streak in the night sky, a SpaceX Falcon 9 rocket carrying Firefly Aerospace’s Blue Ghost Mission One lander soars upward after liftoff from Launch Complex 39A at NASA’s Kennedy Space Center in Florida on Wednesday, Jan. 15, as part of NASA’s CLPS (Commercial Lunar Payload Services) initiative. The Blue Ghost lander will carry 10 NASA science and technology instruments to the lunar surface to further understand the Moon and help prepare for future human missions.Credit: NASA/Frank Michaux A suite of NASA scientific investigations and technology demonstrations is on its way to our nearest celestial neighbor aboard a commercial spacecraft, where they will provide insights into the Moon’s environment and test technologies to support future astronauts landing safely on the lunar surface under the agency’s Artemis campaign.
Carrying science and tech on Firefly Aerospace’s first CLPS or Commercial Lunar Payload Services flight for NASA, Blue Ghost Mission 1 launched at 1:11 a.m. EST aboard a SpaceX Falcon 9 rocket from Launch Complex 39A at the agency’s Kennedy Space Center in Florida. The company is targeting a lunar landing on Sunday, March 2.
“This mission embodies the bold spirit of NASA’s Artemis campaign – a campaign driven by scientific exploration and discovery,” said NASA Deputy Administrator Pam Melroy. “Each flight we’re part of is vital step in the larger blueprint to establish a responsible, sustained human presence at the Moon, Mars, and beyond. Each scientific instrument and technology demonstration brings us closer to realizing our vision. Congratulations to the NASA, Firefly, and SpaceX teams on this successful launch.”
Once on the Moon, NASA will test and demonstrate lunar drilling technology, regolith (lunar rocks and soil) sample collection capabilities, global navigation satellite system abilities, radiation tolerant computing, and lunar dust mitigation methods. The data captured could also benefit humans on Earth by providing insights into how space weather and other cosmic forces impact our home planet.
“NASA leads the world in space exploration, and American companies are a critical part of bringing humanity back to the Moon,” said Nicola Fox, associate administrator, Science Mission Directorate, NASA Headquarters in Washington. “We learned many lessons during the Apollo Era which informed the technological and science demonstrations aboard Firefly’s Blue Ghost Mission 1 – ensuring the safety and health of our future science instruments, spacecraft, and, most importantly, our astronauts on the lunar surface. I am excited to see the incredible science and technological data Firefly’s Blue Ghost Mission 1 will deliver in the days to come.”
As part of NASA’s modern lunar exploration activities, CLPS deliveries to the Moon will help humanity better understand planetary processes and evolution, search for water and other resources, and support long-term, sustainable human exploration of the Moon in preparation for the first human mission to Mars.
There are 10 NASA payloads flying on this flight:
Lunar Instrumentation for Subsurface Thermal Exploration with Rapidity (LISTER) will characterize heat flow from the interior of the Moon by measuring the thermal gradient and conductivity of the lunar subsurface. It will take several measurements to about a 10-foot final depth using pneumatic drilling technology with a custom heat flow needle instrument at its tip. Lead organization: Texas Tech University Lunar PlanetVac (LPV) is designed to collect regolith samples from the lunar surface using a burst of compressed gas to drive the regolith into a sample chamber for collection and analysis by various instruments. Additional instrumentation will then transmit the results back to Earth. Lead organization: Honeybee Robotics Next Generation Lunar Retroreflector (NGLR) serves as a target for lasers on Earth to precisely measure the distance between Earth and the Moon. The retroreflector that will fly on this mission could also collect data to understand various aspects of the lunar interior and address fundamental physics questions. Lead organization: University of Maryland Regolith Adherence Characterization (RAC) will determine how lunar regolith sticks to a range of materials exposed to the Moon’s environment throughout the lunar day. The RAC instrument will measure accumulation rates of lunar regolith on the surfaces of several materials including solar cells, optical systems, coatings, and sensors through imaging to determine their ability to repel or shed lunar dust. The data captured will allow the industry to test, improve, and protect spacecraft, spacesuits, and habitats from abrasive regolith. Lead organization: Aegis Aerospace Radiation Tolerant Computer (RadPC) will demonstrate a computer that can recover from faults caused by ionizing radiation. Several RadPC prototypes have been tested aboard the International Space Station and Earth-orbiting satellites, but now will demonstrate the computer’s ability to withstand space radiation as it passes through Earth’s radiation belts, while in transit to the Moon, and on the lunar surface. Lead organization: Montana State University Electrodynamic Dust Shield (EDS) is an active dust mitigation technology that uses electric fields to move and prevent hazardous lunar dust accumulation on surfaces. The EDS technology is designed to lift, transport, and remove particles from surfaces with no moving parts. Multiple tests will demonstrate the feasibility of the self-cleaning glasses and thermal radiator surfaces on the Moon. In the event the surfaces do not receive dust during landing, EDS has the capability to re-dust itself using the same technology. Lead organization: NASA’s Kennedy Space Center Lunar Environment heliospheric X-ray Imager (LEXI) will capture a series of X-ray images to study the interaction of solar wind and the Earth’s magnetic field that drives geomagnetic disturbances and storms. Deployed and operated on the lunar surface, this instrument will provide the first global images showing the edge of Earth’s magnetic field for critical insights into how space weather and other cosmic forces surrounding our planet impact it. Lead organizations: NASA’s Goddard Space Flight Center, Boston University, and Johns Hopkins University Lunar Magnetotelluric Sounder (LMS) will characterize the structure and composition of the Moon’s mantle by measuring electric and magnetic fields. This investigation will help determine the Moon’s temperature structure and thermal evolution to understand how the Moon has cooled and chemically differentiated since it formed. Lead organization: Southwest Research Institute Lunar GNSS Receiver Experiment (LuGRE) will demonstrate the possibility of acquiring and tracking signals from Global Navigation Satellite System constellations, specifically GPS and Galileo, during transit to the Moon, during lunar orbit, and on the lunar surface. If successful, LuGRE will be the first pathfinder for future lunar spacecraft to use existing Earth-based navigation constellations to autonomously and accurately estimate their position, velocity, and time. Lead organizations: NASA Goddard, Italian Space Agency Stereo Camera for Lunar Plume-Surface Studies (SCALPSS) will use stereo imaging photogrammetry to capture the impact of rocket plume on lunar regolith as the lander descends on the Moon’s surface. The high-resolution stereo images will aid in creating models to predict lunar regolith erosion, which is an important task as bigger, heavier payloads are delivered to the Moon in close proximity to each other. This instrument also flew on Intuitive Machine’s first CLPS delivery. Lead organization: NASA’s Langley Research Center “With 10 NASA science and technology instruments launching to the Moon, this is the largest CLPS delivery to date, and we are proud of the teams that have gotten us to this point,” said Chris Culbert, program manager for the Commercial Lunar Payload Services initiative at NASA’s Johnson Space Center in Houston. “We will follow this latest CLPS delivery with more in 2025 and later years. American innovation and interest to the Moon continues to grow, and NASA has already awarded 11 CLPS deliveries and plans to continue to select two more flights per year.”
Firefly’s Blue Ghost lander is targeted to land near a volcanic feature called Mons Latreille within Mare Crisium, a more than 300-mile-wide basin located in the northeast quadrant of the Moon’s near side. The NASA science on this flight will gather valuable scientific data studying Earth’s nearest neighbor and helping pave the way for the first Artemis astronauts to explore the lunar surface later this decade.
Learn more about NASA’s CLPS initiative at:
https://www.nasa.gov/clps
-end-
Amber Jacobson / Karen Fox
Headquarters, Washington
202-358-1600
amber.c.jacobson@nasa.gov / karen.c.fox@nasa.gov
Natalia Riusech / Nilufar Ramji
Johnson Space Center, Houston
281-483-5111
nataila.s.riusech@nasa.gov / nilufar.ramji@nasa.gov
Antonia Jaramillo
Kennedy Space Center, Florida
321-501-8425
antonia.jaramillobotero@nasa.gov
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Last Updated Jan 15, 2025 LocationNASA Headquarters Related Terms
Commercial Lunar Payload Services (CLPS) Artemis Earth's Moon Johnson Space Center Kennedy Space Center Lunar Science Science & Research Science Mission Directorate View the full article
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